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Minimizing Production Shutdowns through Effective Application and Maintenance

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Minimizing Production Shutdowns through Effective Application and
Maintenance of Safety Pit Coatings

Alex W. Lowery 1, George Stavnes 2
1 Wise Chem LLC, New Albany, Ohio, USA,
2 Pyrotek Inc., Spokane Valley, Washington, USA

Track: BILLET PROCESS & EQUIPMENT - Casting, Casthouse, Environmental Health & Safety

ABSTRACT—Industry-sponsored testing has proven that specific organic coatings (e.g., Wise
Chem E-212-F) applied on concrete and steel substrates assist in the prevention of molten metal
water explosions in aluminum plants. Upon repeated exposures, the coating surface sacrifices
itself upon contact with molten metal to prevent an explosion from occurring. Eventually, the
coating surface exposes the bare substrate (e.g., concrete, steel, stainless steel). Additional studies
have shown that a bare spot as small as 4 square inches (25.4 sq. cm) in the safety pit coating
surface can be an ignition source for a molten metal explosion. Repair of the damaged coating
surface was time consuming and commonly affected production. Recent introduction of Wise
Chem repair kits enable the quick repair of a damaged coating surface. They have minimized, and
in most instances eliminated, any disruption in production. In addition, proper cleaning, surface
preparation, and application of the safety pit coating can minimize production shutdowns and
extend life cycle of safety coatings.

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